- Systematic DFMA (Design for Manufacturing and Assembly) deployment is proposed as a back-to-basics approach to reduce costs and increase profits in manufacturing through design changes. - Key aspects of a systematic DFMA deployment include establishing organizational support and accountability, selecting high-impact projects, allocating resources, executing projects through 5 milestones, and tracking savings. - When done systematically and considering organizational factors, DFMA can yield part count reductions of 20-50%, labor time reductions of 20-60%, and cost savings of 20-50% across industries.

7. 1. Waste of overproduction (of parts) 2. Waste of time on hand - waiting (for parts) 3. Waste in transportation (of parts) 4. Waste of processing itself (parts) 5. Waste of stock on hand – inventory (of parts) 6. Waste of movement (from parts) 7. Waste of making defective products (using parts) Cartoons from Suzaki, The New Manufacturing Challenge , 1987. Wastes from Ohno, Toyota Production System, Beyond Large-Scale Production , 1978 (Japanese), 1988 (English). Breadth of Factory Savings is Staggering Introduce a low waste design to your lean folks

8. 1. Waste of overproduction (of designs) 2. Waste of time on hand - waiting (for designs) 3. Waste in transportation (of designs) 4. Waste of processing itself (designs) 5. Waste of stock on hand – inventory (of designs) 6. Waste of movement (from designs) 7. Waste of making defective designs Cartoons from Suzaki, The New Manufacturing Challenge , 1987. Wastes from Ohno, Toyota Production System, Beyond Large-Scale Production , 1978 (Japanese), 1988 (English). Breadth of Engineering Savings is Staggering Fewer parts to design

9. Business Metrics - profit per square foot, warranty cost per unit

12. Systematic DFMA Deployment What is it? How to do it?

13. Systematic Methodologies Lean, Six Sigma, DFMA Deployment Lean Six Sigma Design for Six Sigma DFMA Deployment Cost Quality Manufacturing Process Product Design

14. Systematic Methodologies Lean, Six Sigma, DFMA Deployment Lean Six Sigma Design for Six Sigma DFMA Deployment Cost Quality Manufacturing Process Product Design e.g., warranty cost reduced, fewer opportunities for defects RTY no missing fasteners = (Yield for a single fastener) number of fasteners Number of defects = probability of a defect x number of opportunities

16. Organization Infrastructure Tools Company-wide Savings from Systematic DFMA Deployment Business Processes Quadrants of Systematic DFMA Deployment Design Engineering leads the work Experts within Design Engineering or on a separate team How many DFMA Black Belts How many DMFA Master Black Belts How to define accountability How to allocate resources How to involve the supply base How to start the initiative How to select projects How to plan and staff projects How to execute projects How to manage and pace projects How to manage software licenses How to share (and not share) DFMA analyses How to share special processes How to share the learning How to track savings How to start the initiative How to select projects How to plan and staff projects How to execute projects How to manage and pace projects

20. Savings and Resources are Different for Project Types DFA of existing sub assemblies DFA of existing products DFA/DFM in New Product Development 20-50% savings 0.2 – 0.5 savings factor, S Purchasing Suppliers Manufacturing 2% savings 0.02 DFMA savings factor, S 5% savings 0.05 DFMA savings factor, S 15% savings 0.15 DMFA savings factor 10% savings 0.1 DFMA savings factor, S Purchasing, Engineering, Manufacturing, Suppliers Purchasing, Engineering. Assembly, Suppliers Almost Everyone Purchasing, Engineering. Assembly, Suppliers Opportunistic Systematic Systematic Opportunistic Target Costing, Cost Negotiation DFM of existing parts (design change) Savings and Resources

21. Savings = S x (labor + materials) x D A contrived example of yearly savings for a range of deployment levels and project portfolios for and example company with Total company Labor + Materials = $100 Million